Modular airfoil system

ABSTRACT

A modular wing, adapted to be used on a flying device such as a toy airplane, drone, or other small fixed wing flying device, or form a part of a wind turbine or any other apparatus that requires a wing or blade, that is compatible with all block-based toy systems such as LEGO®, DECOOL® or KAZI®. The modular wing is comprised of a series of modular aerodynamic surfaces that may be suitable for manufacture by a low-cost method such as molding or additive manufacturing such as 3D printing, typically but not necessarily from plastic, to form wing sub elements which, when assembled together, form a wing or blade such as an airplane wing or turbine blade. The modular wing may comprise cambered or symmetric wing shapes. The modular wing may be used in a static display model fully flying aerodynamic aircraft, sailing hydrodynamic boat, or aerodynamic functioning turbine.

CROSS REFERENCE TO RELATED APPLICATIONS AND INCORPORATION BY REFERENCE

This non-provisional patent application filed in the United StatesPatent and Trademark Office (USPTO) is a continuation of U.S. patentapplication Ser. No. 16/439,644 entitled “MODULAR AIRFOIL SYSTEM” whichwas filed in the USPTO on Jun. 12, 2019, which published from the USPTOon Dec. 12, 2019 as U.S. Patent Publication No. US 2019-0374868 A1, andwhich issued from the USPTO as U.S. Pat. No. 11,583,782 on Feb. 21,2023, which is incorporated by reference herein in its entirety; Ser.No. 16/439,644 is a non-provisional of, and claims the benefit to, U.S.provisional patent application 62/684,103 entitled “MODULAR AIRFOILSYSTEM”, which was filed in the USPTO on Jun. 12, 2018, and which isalso incorporated herein by reference in its entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISKBACKGROUND OF THE INVENTION 1. Field of the Invention

The field of the invention relates generally to wings, rotors or turbineblades which may be assembled from modular components and attached toother structures such as a fixed wing airplane fuselage or rotor orturbine support structure. Additionally, in an embodiment, the modularwing of the invention is adaptable to be used in conjunction withmodular toy assembly systems such as, for example and not by way oflimitation, systems which utilize stud and receiver type assemblystructures.

2. Background Art

There exists in the prior art systems for assembling reconfigurablestructures, such as, for example, those known as LEGO®, DECOOL® orKAZI®. These reconfigurable systems typically utilize a means forassembling two or more elements together using one or more, andtypically, a plurality of attaching structures that each comprise a studor dowel on a first structure that is adapted to be received by arecess, or hole, on a second structure. The recess or hole is adapted toreceive the stud or dowel in a slight press fit such that when a stud ordowel is pressed into a recess, or hole, a removable attachment iscreated between the stud or dowel and the recess or hole. In the casewhere a plurality of stud-recess or dowel-hole pairs are utilized, thestud and recess structures are typically arranged in a predefinedpattern, enabling a plurality of stud and recess structures to bepressed together forming a removable attachment between them. Thepredefined pattern may be, for, example, arranged on a grid pattern,allowing the first and second structures to be reconfigured by detachingthem, rotating them relative to one another by 180 degrees, andre-attaching them by pressing them together. The first structure and thesecond structure may each comprise a plurality of such stud-recesspairs. Thus, when a first structure comprising a plurality of studstructures is pressed against a second structure comprising a pluralityof recess structures, the first and second structures are removablyattached to one another. This method for assembly of structures togethermay be termed a “stud-and-receiver”, “dowel-hole”, or “stud-recess”structure, although there exist other terms in the art that may refer tothe same structure.

Toy systems such as LEGO®, DECOOL® or KAZI® utilize the stud-receiverstructure. These systems are typically used to create passive resultingstructures for use in displays and the like. The resulting structuresare easily reconfigurable. Some structures are not passive and maycomprise moving parts, such as toy robots configured from thestud-recess structure. These robots may contain small motors and rotaryjoints enabling articulation of portions of the assembled structure.

However, there are no past or existing structures that are adapted tocreate wings, blades, or any air foil structure such that it is possibleto assemble a reconfigurable airplane, submarine or other structure thathas wings, blades or such air foils. It would be desirable that theconcept of rapidly reconfigurable structures be extended to the assemblyof structures that utilize wings or blades such as, for example,airplane wing structures, wind mills, wind turbines, rotary wingaircraft or other structures, enabling the reconfigurable assembly offixed and rotary wing aircraft and vehicles for use in water utilizingsuch wings, blades or air foils. It would be further desirable that thewings or blades be modular so that they may be utilized to create alarge variety of diverse structures quickly at the desire of the user.

The present invention overcomes these shortcomings of the prior art. Thepresent invention's ability to enable rapid reconfiguration of a wing,blade, aircraft, windmill or other aerodynamic or hydrodynamic capablestructure, which is not currently in the art, allows for reconfigurationof toys and rapid prototyping without the need for tools.

BRIEF SUMMARY OF THE INVENTION

The present invention comprises an apparatus and method that have one ormore of the following features and/or steps, which alone or in anycombination may comprise patentable subject matter.

The present invention overcomes the shortcomings of the prior art inthat it allows for the quick assembly, disassembly and reconfigurationof wing, blade or foil structures (each of which are individually andcollectively referred to herein simply as a “wing”, “blade” or “foil”)that are usable with stud-and-receiver assembly systems such as thosemanufactured by LEGO®, DECOOL® or KAZI®. The reconfigurable wing orblade structures of the invention allow for the quick build andreconfiguration of desirable apparatuses such as toy airplanes, windmills, and the like which may be mechanically and aerodynamicallyoperable. Furthermore, the reconfigurable wing or blade structures ofthe invention allow for the quick build and reconfiguration ofprototypes that are useful, for example, during aircraft, helicopter,submarine or other vehicle design. For example, an airplane such as atoy airplane may be assembled quickly using a modular wing of theinvention. An airplane thus assembled using the modular wing of theinvention may be able to fly, for example, as a Radio Controlled (RC)airplane. When it is desired to reconfigure the airplane, the modularwing of the invention may be removed from the airplane fuselage easilydue to the use of a stud-recess design of the wing attachment to theaircraft, the wing may be re-configured using its modular components ormay be replaced entirely with an alternate wing having desiredcharacteristics, the modular wing may then be re-attached to thefuselage, and the assembled airplane is immediately ready to fly. Thisprocess of reconfiguration may take mere minutes. In this manner, themodular wing of the invention enables rapid reconfiguration of a toyairplane, windmill, submarine or any structure that utilizes a wing,blade, air foil or other similar structure.

In accordance with one embodiment of the present invention, theinvention comprises modular wing or blade sections that assembletogether to form a completed modular wing or blade. The modular wing orblade is attachable to another structure, such as an airplane fuselageor windmill, using stud-and-receiver assembly structures. Thesestud-and-receiver assembly structures may be, in an embodiment, standardstructures such as those utilized by LEGO®, DECOOL® or KAZI® toybuilding systems.

Historically, toy blocks of the prior art have been a non-functional toydesigned to provide the appearance of mechanical features such asengines, pistons, drives and gears. However the prior art isnon-functional in that it does not provide wing, blade or foil crosssections that generate lift, or provide any aerodynamic of hydrodynamiccross section, that would enable the assembled toy or prototype to flythrough a fluid and produce lift. In contrast, the wing, blade, andairfoil sections and elements of the present invention are novel inthat, among other things, they add an aeronautical element that does notexist with the prior art mechanical design, enabling functional flyingthrough a fluid. Said another way the elements of the present inventionprovide wing, blade or foil cross sections that produce lift whenmotivated through a fluid. Thus the present invention providesaerodynamic surfaces in air or operational hydrodynamic surfaces inwater or any other fluid.

Moreover, the airfoils, wings and blades of the invention are modular,allowing for flexibility during assembly. They can be assembled in allmanner of arrangements, for example: single wings, bi-plane wings,tri-plane wings, box wings, windmill arrangements, propellerarrangements or hydrofoil arrangements etc., using parts of existingavailable toys to provide mating connectivity between airfoils. Thepresent invention is also simple to fabricate: in embodiments, only twoelements of the present invention may provide multiple permutations ofwing planform designs.

The invention overcomes a shortcoming in the prior art in that it iseasily aerodynamically reconfigurable at the desire of the user. Thus,for example, an airplane comprising a modular wing of the invention maystart as a single-wing fixed wing airplane, and then rapidly bereconfigured into a biplane configuration. The present method and deviceof the invention overcome the shortcomings of the prior art by enablingthe rapid assembly and reconfiguration of devices that utilizes wing,blade or foil structures.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated into and form a partof the specification, illustrate one or more embodiments of the presentinvention and, together with the description, serve to explain theprinciples of the invention. The drawings are only for the purpose ofillustrating the preferred embodiments of the invention and are not tobe construed as limiting the invention. In the drawings:

FIG. 1 depicts a perspective view of a sub-element of an embodiment ofthe invention, and an assembly of two sub-elements with the connectingstud-recess elements hidden within structure.

FIG. 2 depicts an example in which six wing sub-elements are attachedtogether to form a full modular wing assembly.

FIG. 3 depicts a plurality of modular wing sub elements attached tostud-recess elements to form a larger span wing, with the connectingstud-recess elements hidden within structure.

FIG. 4 depicts a perspective cross sectional view of an embodiment of amodular wing or blade of the invention depicting wing sub-elementsattached to stud-recess elements via stud-recess element connections atthe front and rear wing spar locations.

FIG. 5 depicts a perspective view of an embodiment of the wingsub-elements attachments using stud-recess elements.

FIG. 6 depicts a perspective view of an embodiment of the invention inwhich flap elements of the invention are attached to wing elements ofthe invention at hinge points. Rear cross dowels are added to lock thesurface in order to provide interconnection of flap to wing elements.

FIG. 7 depicts a perspective view, taken from underneath, of anembodiment of the invention in which flap surfaces comprise provisionsand clearance to allow a variety of different surface lock pins anddrive for control of flap position.

FIG. 8 depicts a perspective view of a large wing sub-element of anembodiment of the invention.

FIG. 9 depicts a perspective view of an exemplary embodiment of aslotted internal socket support structure at each end of the wingsub-element that may be used to allow the wing internal elements tomate. Also depicted is a free vertical member that can be pushed throughholes in the underside of the wing to force the forward and rear sparsto engage on their dowels at the wing spar. This approach may be used tojoin two or more sub elements together, and keeps the attachmentstructure internal to the wing, retaining the aerodynamic orhydrodynamic qualities of the external shape of the wing, blade orairfoil.

FIG. 10 depicts various exemplary embodiments of airplanes, windmillsand other structures which may comprise modular wings or blades of theinvention.

FIG. 11A depicts an exemplary stud-recess/dowel-hole attachment of theinvention, prior to a first structure being removably attached to asecond structure.

FIG. 11B depicts an exemplary stud-recess/dowel-hole attachment of theinvention, after a first structure being removably attached to a secondstructure.

FIG. 11C depicts an exemplary stud-recess/dowel-hole attachment of theinvention, prior to a first structure being removably attached to asecond structure. This uses an optionally large dowel to mount parts onone side as a socket and the other side as a pinned truss.

FIG. 11D depicts an exemplary stud-recess/dowel-hole attachment of theinvention, after a first structure being removably attached to a secondstructure. This uses an optionally large dowel to mount parts on oneside as a socket and the other side as a pinned truss.

FIG. 12 depicts exemplary planforms of cambered and symmetric airfoilshapes and dimensions comprising specific embodiments of the invention.

FIGS. 13-20 depict embodiments of the invention designed for improvedmanufacturability.

In the figures, like callouts refer to like features.

DETAILED DESCRIPTION OF THE INVENTION

The following documentation provides a detailed description of theinvention.

Although a detailed description as provided in the attachments containsmany specifics for the purposes of illustration, anyone of ordinaryskill in the art will appreciate that many variations and alterations tothe following details are within the scope of the invention.Accordingly, the following preferred embodiments of the invention areset forth without any loss of generality to, and without imposinglimitations upon, the claimed invention. Thus the scope of the inventionshould be determined by the appended claims and their legal equivalents,and not merely by the preferred examples or embodiments given.

Generally, the invention may comprise one or more wings or blades thatare each comprised of one or more sub-elements, wherein the wings orblades are directly compatible with, and removably attachable to, blockbased toy systems such as LEGO®, DECOOL® or KAZI®. The invention maycomprise a plurality of modular aerodynamic streamlined surfaces, suchas for example, an airfoil, that can be combined with block based toysystems such as LEGO®, DECOOL® or KAZI® to form static display orfunctional, flying aircraft, wind turbine or airship or rotorcraft orpropeller systems; or static or functional, propulsive hydrofoil orhydrodynamic propeller systems, or automotive lift or downforce systems.The sub-elements of the invention may be, in an embodiment, fabricatedfrom high tolerance plastic injection molding or by 3-D printing oradditive manufacturing. An exemplary material used in producing theinvention is ABS plastic, however other materials may be used. Materialsof construction may have the following properties: specific gravity:1.05 g/cm³, tensile strength: 44 Mpa; and elongation at break between23-25%.

As used herein, “airfoil”, “wing”, “blade” or “foil” means a structurewith a cross-sectional shape that produces an aerodynamic force or fluiddynamic force when motivated through a fluid. The component of thisforce perpendicular to the direction of motivation is called lift.Airfoils may take a number of cross sections as is known in the art.

The part dimensions of the invention may be consistent with existingmating toy system geometry (e.g. the LEGO®, stud-recess removableattachment system). The modular sub-elements may comprise cambered wingsurfaces, symmetrical wing surfaces, and wing tips.

The cambered wing surfaces of the invention may employ anon-symmetrical, cambered airfoil section and trailing edge hinged flapsystem in which a flap or a plurality of flaps are rotably or hingedlyattached to a trailing edge of the modular wing. As non-limitingexamples, the non-symmetrical, cambered airfoil section can be employedas a mono plane, tri-plane, tandem wings, winglets, diamond or boxwings, or combinations thereof, forming a plurality of wingconfigurations.

In an embodiment, the trailing edge flap hinge can be locked to create afixed surface, or can be free to create a hingedly attached movingsurface.

The available cambered airfoil profile designs can be manufactured viamodular manufacturing processes. Likewise, in embodiments, the trailingedge flap, leading edge flap and slat designs may be applied to the wingelements surface through a modular manufacturing process.

The cambered wing sub-elements of the invention can be joined orconnected together to form larger span wings by virtue of their commonconnection system.

During connection, the flaps comprise a quick attachment feature thatallows various semi-spans to be connected to allow interconnecteddriving of the adjacent flap surface, or, the connection can remain freeallowing partial flapped sections of wing. This quick attachment featureis, for example, a stud-recess removable attachment.

The cambered wings may comprise any cambered aerodynamic profile shape;any chord, for example, and not by way of limitation, up to andincluding 1 meter in length and longer; any semi-span for example, andnot by way of limitation, up to 1 meter in length and longer; any wingtaper ratio; and any wing sweep.

The modular sub-elements include a wingtip sub-element. In anembodiment, his wingtip section may be a tip reflecting all current, toyaircraft configurations or as a winglet for all current, toy aircraftwinglet configurations.

All symmetrical wing surfaces may employ a symmetrical, airfoil sectionand proprietary trailing edge hinged flap system. The symmetrical,cambered airfoil section can be employed as a mono plane, tri-plane,tandem wings, winglets, diamond or box wings or combinations thereofwing configurations.

The trailing edge flap hinge may be locked to create a fixed surface, ormay be rotably attached to a modular wing trailing to create a movingsurface adapted to be rotated for example, as a flight control surface.

All available cambered airfoil profile designs may be manufactured viamodular manufacturing processes.

All available trailing edge flap, leading edge flap and slatsub-elements can be applied to the wing elements surface through amodular manufacturing process.

The symmetrical wings can be joined together to form larger span wingsby virtue of their common connection system, which may be, for example,a stud-recess removable attachment.

During connection the flaps have a quick attachment feature that allowsvarious semi-spans to be connected to allow interconnected driving ofthe adjacent flap surface, or, the connection can remain free allowingpartial flapped sections of wing.

The symmetrical wings may be supplied in any cambered aerodynamicprofile shape, for example and not by way of limitation, any chord up to½ meter in length or longer; any semi-span for example and not by way oflimitation up to ½ meter in length or longer; any taper ratio; and anysweep.

Cambered wing sub-elements may also be joined to symmetrical wingsub-elements and vice versa via their modular stud-recess attachmentsystem.

In embodiments of the modular wing system of the invention both camberedand symmetric wing surfaces have provisions for access to their substructure via their lower surfaces. Such access may be provided, forexample, by an opening or aperture in the wing lower surface. The lowersurface aperture may provide access to an internal structure that iscompatible with LEGO®, DECOOL® or KAZI® for providing a removableattachment to a strut by way of a stud-recess removable attachment,allowing external bracing strut attachments to be used. As analternative, such strut attachment to a lower surface of a wingsub-element may be provided by a protuberance or other structure formedin the lower surface of a wing sub-element, wherein such protuberance orother structure is adapted to attach to a strut by way of a stud-recessremovable attachment or other attachment.

In any embodiment, the sub-elements of the system may be removablyattached together using threaded fasteners such as, for example, anycombination of male threaded fasteners and female threaded fasteners.Thus the invention may be assembled onto a toy system that utilizes therecess-stud system or may be assembled onto any structure using threadedfasteners.

Exemplary sub-elements may comprise leading edge (LE) or trailing edge(TE) wing sweeps. Non-limiting, exemplary dimensions for embodiments ofthe invention are:

-   -   WING-LONG-STRAIGHT: Span of 680 mm by 340 mm chord;    -   WING-SHORT-STRAIGHT: Span of 340 mm by 340 mm chord;    -   WING-SHORT-TAPER: Semi-span of 680 mm by 340 mm chord, Left Hand        (LH) Leading Edge (LE) sweep;    -   WING-SHORT-TAPER: Semi-span of 680 mm by 340 mm chord, Right        Hand (RH) Leading Edge (LE) sweep;    -   WING-SHORT-TAPER: Semi-span of 680 mm by 340 mm chord, Left Hand        (LH) Trailing Edge (TE) sweep;    -   WING-SHORT-TAPER: Semi-span of 680 mm by 340 mm chord, Right        Hand (RH) Trailing Edge (TE) sweep;    -   WING TIP: Semi-span of 340 mm chord Left Hand (LH);    -   WING TIP: Semi-span of 340 mm chord Right Hand (RH);    -   WING-LONG-STRAIGHT: Span of 680 mm by 192 mm chord;    -   WING-SHORT-STRAIGHT: Span of 340 mm by 192 mm chord;    -   WING-SHORT-TAPER: Semi-span of 340 mm by 192 mm chord, Left Hand        (LH) Leading Edge (LE) sweep;    -   WING-SHORT-TAPER: Semi-span of 340 mm by 192 mm chord, Right        Hand (RH) Leading Edge (LE) sweep;    -   WING-SHORT-TAPER: Semi-span of 340 mm by 192 mm chord, Left Hand        (LH) Trailing Edge (TE) sweep; and    -   WING-SHORT-TAPER: Semi-span of 340 mm by 192 mm chord, Right        Hand (RH) Trailing Edge (TE) sweep.

Referring now to FIG. 1 , a perspective view of a sub-element of anembodiment of the invention attached via an internal stud-recess elementis depicted. A modular wing or blade of the invention may comprise aplurality of sub-elements removably attached using the stud-recessremovable attachment. In an embodiment, each of these sub elements canbe added together to form larger wing structures adapted to be assembledwith compatible elements from LEGO®, DECOOL® or KAZI®. The result caneither be a static display model with an aerodynamic surface or a fullyflying aerodynamic scale model that can be operated as a remotelycontrolled aircraft or hand thrown glider. Flap sub-element 118 may berotably connected to modular wing sub-element 100 by a dowel, pin, axleor similar structure passing through bearing elements 102 and 103.Stud-recess attachment elements 104 and 105 (shown in FIG. 2 ) may beused to attach flap sub-element 100 to other flap sub-elements, or to anairplane fuselage, or windmill hub, or other structure as may bedesired. The flexibility of the configuration allows the wing subelements to be joined to create aerodynamic wing planform geometries oflimitless combinations. The sub elements 100 can be used to createflying toy or model aircraft comprising wings with airfoil crosssections that produce lift, and thus such toy or model aircraft will befunctional, flying aircraft. The wing sub elements can be combined withother block type toys using stud-recess attachment or other attachmentsystems, or can be used with standard remotely controlled aircraftflight controls and fastener hardware.

Referring now to FIG. 2 , the assembly of two modular wing sub-elements100 of the invention to form a larger wing or blade structure isdepicted. In this figure, the modular wing sub-elements 100 are depictedin the process of being brought together but have not yet been removablyattached to one another. The removable attachment between the twosub-elements 100 is provided by stud-recess attachment elements 104 and105. In this manner, a full wing or blade comprising at least one, andin differing embodiments, a plurality, of sub-elements 100 may beformed. The full wing or blade is reconfigurable by detaching the twowing elements 100 from one another and reconfiguring with differentsub-elements as desired by the user. In this manner, longer or shorterwings or blades can be rapidly configured, allowing rapidreconfiguration and prototyping for meeting desired characteristics ofthe finished structure. As an example, if it desired to configure a wingwith more lift, additional modular wing sections may be added, creatinga longer wing. Flap sub-elements 118 are depicted for reference. Thehinged attachment between sub-elements 100 and 118 and 118 a isdepicted, having an axis of rotation A about which sub-elements 118 andother sub-elements 118 a, and so on, may rotate in the directions shownby arrow B.

Referring now to FIG. 3 , a modular wing of the invention is depicted,wherein two modular wing sub-elements 100 have been assembled togetherin a removable attachment using internal stud-recess attachment elements104 and 105. It is not necessary that the two modular wing sub-elements100 be of the same airfoil design; i.e. they may comprise anycombination of cambered or symmetrical airfoil shaped.

Referring now to FIGS. 4, 5, 6, 8 and 9 , a perspective cross sectionalview of an embodiment of a modular wing or blade sub-element of theinvention, depicting wing sub-elements 100 attached to stud-recesselements via stud-recess element connections at the front and rear sparlocations is depicted. The modular wing sub-element has an upper surface117 and a lower surface 116 that together define an airfoil shape. Themodular wing sub-element may comprise hollow sections or lengthwisevoids 111 a-111 g which each may be separated by a wall, which serve toreduce the weight or mass of modular wing sub-element withoutsignificant loss of strength and stiffness. These voids may runlengthwise through the modular wing sub-element, allowing thesub-element to be fabricated by extrusion. A flap sub-element 118 may beattached to a trailing edge 114 of the modular wing sub-element. Theattachment of flap element 118 to the trailing edge of the modular wingsub-element may be rotable about an axis of rotation A about a pin oraxle (not depicted in FIG. 4 ) that is disposed in lengthwise void 110.Recesses 115 may be disposed in an internal structure of the modularwing, for example in an internal wall of the modular wing, for receivingstuds in a removable stud-recess attachment such as attachment elements104 or 105 (not depicted in FIG. 4 but depicted in FIGS. 1, 2, 3, 5 and6 ) at the interface of surfaces at C and D, respectively. Modular wingsub-element leading edge 113, which is the leading edge of motivationfor purposes of defining the direction of motivation of the airfoil ofthe invention through a fluid, is shown for reference. Flap sub-element118 may comprise a flap receiving feature 119 is depicted as a “cross”cross section, but may be any cross sectional shape, and may be used toreceiving a locking structure of complementary cross section in, forexample, a sliding or slight press fit, allowing adjacent flaps to belocked together such that they may operate as a unitary structure,rotable about the axis formed by a dowel or pin running throughlengthwise void 110, forming a hinge. A first end of an optional supportstrut 106 comprising stud-recess attachment elements which may beattached to a lower surface of a modular wing sub-element or to astructure internal to the modular wing sub-element using a stud-recessattachment. This may require the skin to be cut by the user, or ifaligned with the skin access holes 122, this can mate to elementsattached to the spar 106 that extend through these holes. A second endof spar 106 may be attached to a supporting structure, such as, by wayof example, a fuselage. FIG. 9 depicts a perspective view of anexemplary embodiment of the slotted internal socket support structure ateach end of the wing sub-element that is used to align the wing tointernal elements. Also depicted is a free vertical member 123 that canbe pushed through skin access holes 122 or 600 in the underside of thewing. The vertical action forcing the forward and rear spars to engageon their dowels while seated in the socket through the wing spar. Thisis used to join two internal sub elements together. The free verticalmember 123 is then removed.

Referring now to FIG. 7 , a perspective view, taken from underneath, ofan embodiment of the invention in which flap surfaces compriseprovisions and clearance to allow a surface lock pins and drives forcontrol of flap position is depicted. Modular flap sub-element 110 maybe hingedly or rotably attached to a trailing edge of a modular wingsub-element 100 by a pin or dowel inserted lengthwise through receivingstructures in both the flag sub-element 118 and the trailing edge of thewing sub-element 100 forming axis of rotation A enabling rotation ofsub-element 118 as depicted by arrows B. The pin or dowel (not depictedin FIG. 7 ) has a longitudinal axis that forms an axis of rotation A ofthe flap sub-element 118 relative to wing sub-element 100. To controlthe rotation B of the flap sub-element 118, it may be desirable toattach a strut sub-element (not depicted in FIG. 7 ). The strutsub-element may be attached to an underneath surface of flap 118 by aremovable cross attachment 121 disposed in a structural protuberance 120that is a part of, or attached to, an underneath surface of flapsub-element 118. The lower, or underneath, airfoil surface 116 of wingsub-element 100 is called out in the figure for reference.

Referring now to FIG. 10 , four exemplary structures comprising modularwing or blade assemblies of the invention are depicted. These exemplarystructures are non-limiting; i.e. they are examples of but a few of themany structures which may comprise modular wing or blade assemblies ofthe invention. Each of the structures may comprise one or more wingsub-elements 100 or wing-tip sub-elements 101 as may be desired by auser. Thus, a monoplane structure 500, bi-plane structure 501, wind millstructure 502, or hydrofoil structure 503 may be created as desired bythe user, using various combinations of the wing or blade sub-elements100 and wing tip sub-elements 101.

Referring now to FIGS. 11A and 11B, an embodiment of a non-limiting,exemplary stud-recess attachment of the invention is depicted. A firstelement or sub-element 001 may be attached to a second element orsub-element 002 by means of a socket 003 in first element 001 beinginserted into a receiving recess 004 in second element 002 when firstelement 001 is motived towards second element 002 in the direction ofarrow A. The fit between the outer dimension of stud 003 and innerdimension of recess 004, depicted as dimension B, may be a sliding fit,a slight press fit, or a full press fit resulting in a removableattachment between first element 001 and second element 002. In anembodiment, a permanent attachment may be realized between first element001 and second element 002 by choosing the fit between the outerdimension of stud 003 and inner dimension of recess 004, depicted asdimension B to result in an interference fit between the outer dimensionof stud 003 and inner dimension of recess 004 that a permanentattachment is formed between first element 001 and second element 002,and being locked in place by dowel element 005 FIG. 11B depicts acompleted attachment between first element 001 and second element 002utilizing a stud-recess attachment, which may result in either apermanent or a removable attachment between first element 001 and secondelement 002 and is locked in place by dowel element 005.

Referring now to FIGS. 11C and 11D, a non-limiting, exemplarystud-recess attachment of the invention is depicted. A first element 001may be attached to a second element 002 by means of a socket 003 infirst element 001 being inserted into a receiving “recess” 004 in secondelement 002 when first element 001 is motived towards second element 002in the direction of arrow A. The fit between the outer dimension of stud003 and inner dimension of recess 004, depicted as dimension B, may be asliding fit, a slight press fit, or a full press fit resulting in aremovable attachment between first element 001 and second element 002.In an embodiment, a permanent attachment may be realized between firstelement 001 and second element 002 by choosing the fit between the outerdimension of stud 003 and inner dimension of recess 004, depicted asdimension B to result in an interference fit between the outer dimensionof stud 003 and inner dimension of recess 004 that a permanentattachment is formed between first element 001 and second element 002,and being locked in place by dowel element 006. In addition as the dowelelement is longer an additional element 002 can be attached to the rearto reduce the load in the socketed element. FIG. 11D depicts a completedattachment between first element 001 and second element 002 utilizing astud-recess attachment, which may result in either a permanent or aremovable attachment between first element 001 and second element 002and is locked in place by dowel element 006.

Referring now to FIG. 12 , typical dimensions for cambered andsymmetrical sub-elements of the invention are depicted. These dimensionsare depicted as exemplary, and not as limiting.

FIG. 13 depicts one embodiment of a wing or airfoil of the invention.FIGS. 14-20 depict an alternate embodiment of the invention.

FIGS. 14 and 17-20 depict an embodiment of the invention in which a topportion of the airfoil sub-element and a bottom portion of the airfoilsub-element are fabricated separately and then assembled together tocreate a completed sub-element.

FIG. 14 depicts an alternate embodiment of the invention in which amodular wing of the invention, adapted to be used on a flying devicesuch as a toy airplane, drone, or other small fixed wing flying device,or form a part of a wind turbine or any other apparatus that requires awing or blade, is compatible with block-based toy systems such as LEGO®,DECOOL® or KAZI® utilizing stud-and-receiver attachment. The modularwing may be comprised of a series of modular aerodynamic surfaces thatmay be suitable for manufacture by a low-cost method such as molding oradditive manufacturing such as 3D printing, typically but notnecessarily from plastic, to form wing sub elements which, whenassembled together, form a wing or blade such as an airplane wing orturbine blade. The modular wing may comprise cambered or symmetric wingshapes, the updated version being formed by a manufacturing process thatcaptures the toy brick elements within the design 601, 602. The toybrick elements comprise receiver features in order to accomplishstud-and-receiver attachment with, for example, stud-recess attachmentelements 104 and 105 as depicted in FIG. 2 . The alternate embodiment ofFIG. 14 includes the options for two embedded bricks, howeverembodiments of the invention may include options for containing anynumber of embedded bricks. In this figure item 601 is a front embeddedbrick and item 602 is a rear embedded brick. By utilizing this approachfor capturing embedded bricks within a wing element or sub-element ofthe invention, low-cost manufacturing processes such as extruding,molding, and 3-D printing are enabled.

FIGS. 15 and 16 depict alternative embodiments of an airfoil of theinvention in which the airfoil is manufactured by any manufacturingprocess including but not limited to 3D printing, molding includinginjection molding, extrusion or any other manufacturing process, andthen folded into shape.

FIG. 15 depicts a view of a folded alternate embodiment of a flap of theinvention designed for production manufacturing process. Thisalternative flap configuration is comprised of a male and femaleassembly where the part may be fabricated as a flat piece that is thenfolded about the trailing edge of the part. In FIG. 15 , item 603 is amale and female assembly; item 604 is a web; item 605 retains theoriginal hinge hole design; item 606 is a thin embodiment of the skin;item 607 is the folded trailing edge which enabled to fold along foldaxis E indirection F due to the cross section of skin along folding edge607 to be thin enough to allow folding without rupture or othermechanical failure of the material comprising the sub-element which maybe, for example, any plastic. Features of this embodiment may includemale and female complementary features that are engaged in press fit orsnap fit captured the folded portions together

FIG. 16 depicts a view of an unfolded flap embodiment designed forproduction manufacturing process. The unfolded configuration iscomprised of a part that can be injection molded in one piece. Item 608is a groove. Item 609 are male ‘stays’ for male to female assembly intoreceiving complementary groove(s) 608 in a press fit when folded aboutfold axis G in direction H. Item 610 is a thin embodiment of the skin.

FIG. 17 depicts an alternate embodiment of a main upper airfoilconfiguration, designed for production manufacturing process. The upperairfoil configuration is unconnected to lower airfoil surface. The baseand upper surface can be separated to improve general accessibility.General configuration as previously defined below. The part may beformed from one piece of extruded plastic. Item 611 is a web element.Item 612 is a thin embodiment of the skin.

FIG. 18 depicts an alternate embodiment of the main lower airfoilconfiguration which is designed for production manufacturing process. Inthis view the lower airfoil is unconnected to upper airfoil surface. Thebase and upper surface may be separated to improve generalaccessibility. Item 613 is a web. Item 614 is a brick captured byfeatures 601 and 602. Male features 700 are adapted to create a pressfit with complementary female features located in underneath surfaces ofthe upper portion the airfoil when motivated towards and against theunderneath surface of the upper portion of the airfoil in a press orsnap fit. Thus the upper portion of the airfoil depicted in FIG. 17 andthe lower portion of the airfoil depicted in FIG. 18 are assembledtogether in a press fit or snap fit, resulting in an assembled air foilas depicted in FIG. 14 .

FIG. 19 depicts an example of a capture location. Item 615 is an uppersurface at a capture location with the brick not installed. Item 616 isa lower surface at a capture location with the brick not installed.

FIG. 20 depicts a sample of a capture location with the bricksinstalled. The number and location of such capture locations may varydepending on airfoil size. Any quantity and location is covered by thedesign. Item 617 may be any brick, for example, a mating spar brickcomprising a stud and recess capture scheme, joining ‘n’ brick to ‘sparbrick at top two stud holes. Item 618 is a brick comprising a stud andrecess capture scheme, joining lower surface to bottom two stud holes.Item 619 is a lower surface at a capture location, with the brick notinstalled. Item 620 is a lower surface at capture location, with brickinstalled.

INDUSTRIAL APPLICABILITY

The present invention solves the problem of providing rapidlyreconfigurable, inexpensive, wing or blade structures for attachment toairplane structures, wind mill or wind turbine structures, rotaryaircraft structures, or other structures as may be desired by a user.

The invention comprises a modular wing, adapted to be used on a flyingdevice such as a toy airplane, drone, or other small fixed wing flyingdevice, or form a part of a wind turbine or any other apparatus thatrequires a wing or blade, that is compatible with all block-based toysystems such as LEGO®, DECOOL® or KAZI®. The modular wing is comprisedof a series of modular aerodynamic surfaces that may be suitable formanufacture by a low-cost method such as molding or additivemanufacturing such as 3D printing, typically but not necessarily fromplastic, to form wing sub elements which, when assembled together, forma wing or blade such as an airplane wing or turbine blade.

The modular wing or blade of the invention may comprise either camberedor symmetric wing shapes. The modular wing may be used in a staticdisplay model or a fully flying aerodynamic aircraft.

The flexibility of the configuration allows the wing sub elements to bejoined to create aerodynamic wing planform geometries of limitlesscombinations.

What is claimed is:
 1. A modular airfoil system, comprising: at leastone sub-element shaped as a section of an airfoil wherein said at leastone sub-element is removably attachable to a structure, and wherein saidat least one sub-element comprises a upper surface and a lower surface,a first end face and a second end face; wherein said upper surface and alower surface together form an airfoil having a cross section.
 2. Themodular airfoil system of claim 1, wherein said removable attachment isfurther defined as comprising a stud-recess/dowel-hole attachment. 3.The modular airfoil system of claim 1, wherein said cross section isfurther defined as forming a cambered airfoil.
 4. The modular airfoilsystem of claim 1, wherein said cross section is further defined asforming a symmetrical airfoil.
 5. The modular airfoil system of claim 2,wherein said cross section is further defined as forming a camberedairfoil.
 6. The modular airfoil system of claim 2, wherein said crosssection is further defined as forming a symmetrical airfoil.
 7. Themodular airfoil system of claim 1, further defined as comprising aplurality of sub-elements selected from the group consisting of acambered wing sub-element, a modular wing sub-element, and a wing tip;and wherein each sub-element is removably attached to an adjoiningsub-element in an end face to end face connection which the end face ofa first sub-element is adjacent to an end face of a second sub-element,and wherein each sub-element is attached to an adjacent sub-element by aconnecting sub-element that is removably attached to each sub-element bya stud-recess/dowel-hole connection.
 8. The modular airfoil system ofclaim 2, further defined as comprising a plurality of sub-elementsselected from the group consisting of a cambered wing sub-element, amodular wing sub-element, and a wing tip; and wherein each sub-elementis removably attached to an adjoining sub-element in an end face to endface connection which the end face of a first sub-element is adjacent toan end face of a second sub-element, and wherein each sub-element isattached to an adjacent sub-element by a connecting sub-element that isremovably attached to each sub-element by a stud-recess/dowel-holeconnection.
 9. The modular airfoil system of claim 3, further defined ascomprising a plurality of sub-elements selected from the groupconsisting of a cambered wing sub-element, a modular wing sub-element,and a wing tip; and wherein each sub-element is removably attached to anadjoining sub-element in an end face to end face connection which theend face of a first sub-element is adjacent to an end face of a secondsub-element, and wherein each sub-element is attached to an adjacentsub-element by a connecting sub-element that is removably attached toeach sub-element by a stud-recess/dowel-hole connection.
 10. The modularairfoil system of claim 4, further defined as comprising a plurality ofsub-elements selected from the group consisting of a cambered wingsub-element, a modular wing sub-element, and a wing tip; and whereineach sub-element is removably attached to an adjoining sub-element in anend face to end face connection which the end face of a firstsub-element is adjacent to an end face of a second sub-element, andwherein each sub-element is attached to an adjacent sub-element by aconnecting sub-element that is removably attached to each sub-element bya stud-recess/dowel-hole connection.
 11. The modular airfoil system ofclaim 5, further defined as comprising a plurality of sub-elementsselected from the group consisting of a cambered wing sub-element, amodular wing sub-element, and a wing tip; and wherein each sub-elementis removably attached to an adjoining sub-element in an end face to endface connection which the end face of a first sub-element is adjacent toan end face of a second sub-element, and wherein each sub-element isattached to an adjacent sub-element by a connecting sub-element that isremovably attached to each sub-element by a stud-recess/dowel-holeconnection.
 12. The modular airfoil system of claim 6, further definedas comprising a plurality of sub-elements selected from the groupconsisting of a cambered wing sub-element, a modular wing sub-element,and a wing tip; and wherein each sub-element is removably attached to anadjoining sub-element in an end face to end face connection which theend face of a first sub-element is adjacent to an end face of a secondsub-element, and wherein each sub-element is attached to an adjacentsub-element by a connecting sub-element that is removably attached toeach sub-element by a stud-recess/dowel-hole connection.
 13. The modularairfoil system of claim 1, wherein each of said cambered and each ofsaid symmetrical airfoil sub-elements are further defined as having anairfoil trailing edge, and wherein the trailing edge of each of saidcambered airfoil sub-elements and each of said symmetrical airfoilsub-elements comprises a receiving structure for receiving a flap in anrotable attachment.
 14. The modular airfoil system of claim 2, whereineach of said cambered and each of said symmetrical airfoil sub-elementsare further defined as having an airfoil trailing edge, and wherein thetrailing edge of each of said cambered airfoil sub-elements and each ofsaid symmetrical airfoil sub-elements comprises a receiving structurefor receiving a flap in an rotable attachment.
 15. The modular airfoilsystem of claim 3, wherein each of said cambered and each of saidsymmetrical airfoil sub-elements are further defined as having anairfoil trailing edge, and wherein the trailing edge of each of saidcambered airfoil sub-elements and each of said symmetrical airfoilsub-elements comprises a receiving structure for receiving a flap in anrotable attachment.
 16. The modular airfoil system of claim 4, whereineach of said cambered and each of said symmetrical airfoil sub-elementsare further defined as having an airfoil trailing edge, and wherein thetrailing edge of each of said cambered airfoil sub-elements and each ofsaid symmetrical airfoil sub-elements comprises a receiving structurefor receiving a flap in an rotable attachment.
 17. The modular airfoilsystem of claim 5, wherein each of said cambered and each of saidsymmetrical airfoil sub-elements are further defined as having anairfoil trailing edge, and wherein the trailing edge of each of saidcambered airfoil sub-elements and each of said symmetrical airfoilsub-elements comprises a receiving structure for receiving a flap in anrotable attachment.
 18. The modular airfoil system of claim 6, whereineach of said cambered and each of said symmetrical airfoil sub-elementsare further defined as having an airfoil trailing edge, and wherein thetrailing edge of each of said cambered airfoil sub-elements and each ofsaid symmetrical airfoil sub-elements comprises a receiving structurefor receiving a flap in an rotable attachment.
 19. The modular airfoilsystem of claim 7, wherein each of said cambered and each of saidsymmetrical airfoil sub-elements are further defined as having anairfoil trailing edge, and wherein the trailing edge of each of saidcambered airfoil sub-elements and each of said symmetrical airfoilsub-elements comprises a receiving structure for receiving a flap in anrotable attachment.
 20. The modular airfoil system of claim 8, whereineach of said cambered and each of said symmetrical airfoil sub-elementsare further defined as having an airfoil trailing edge, and wherein thetrailing edge of each of said cambered airfoil sub-elements and each ofsaid symmetrical airfoil sub-elements comprises a receiving structurefor receiving a flap in an rotable attachment.
 21. The modular airfoilsystem of claim 9, wherein each of said cambered and each of saidsymmetrical airfoil sub-elements are further defined as having anairfoil trailing edge, and wherein the trailing edge of each of saidcambered airfoil sub-elements and each of said symmetrical airfoilsub-elements comprises a receiving structure for receiving a flap in anrotable attachment.
 22. The modular airfoil system of claim 10, whereineach of said cambered and each of said symmetrical airfoil sub-elementsare further defined as having an airfoil trailing edge, and wherein thetrailing edge of each of said cambered airfoil sub-elements and each ofsaid symmetrical airfoil sub-elements comprises a receiving structurefor receiving a flap in an rotable attachment.
 23. The modular airfoilsystem of claim 11, wherein each of said cambered and each of saidsymmetrical airfoil sub-elements are further defined as having anairfoil trailing edge, and wherein the trailing edge of each of saidcambered airfoil sub-elements and each of said symmetrical airfoilsub-elements comprises a receiving structure for receiving a flap in anrotable attachment.
 24. The modular airfoil system of claim 12, whereineach of said cambered and each of said symmetrical airfoil sub-elementsare further defined as having an airfoil trailing edge, and wherein thetrailing edge of each of said cambered airfoil sub-elements and each ofsaid symmetrical airfoil sub-elements comprises a receiving structurefor receiving a flap in an rotable attachment.
 25. The modular airfoilsystem of any of claim 13, wherein each of said trailing edges form acomposite contiguous trailing edge; and wherein said modular airfoilsystem further comprising a flap extending along at least a portion ofsaid composite trailing edge, said flap connected to said compositetrailing in a rotable attachment.
 26. The modular airfoil system ofclaim of claim 13, further comprising an opening in the lower surface ofat least one of said sub-elements for allowing a connecting element topass there through and to attach to an internal structure of saidsub-element in a stud-recess attachment.